JP2013530075A - Cement product packaging - Google Patents

Abstract

The present invention provides a method for processing a cement product to substantially reduce or eliminate white flower. The method includes applying a protective layer to at least one surface of the slab product and holding the protective layer in place when the cement kneaded material is cast into a mold. The protective layer is a relatively thin sheet made of a plastic material.
[Selection] Figure 11

Description

  The present invention relates generally to cement products.

  Currently, the process of manufacturing cement products, such as tiles, in small individual molds remains substantially the same as the fabrication methods used in the past 50 years and is still prevalent throughout the world.

  However, over the last 20 years, the development of tile production has resulted in tiles with a much more modern look, corresponding to the trends and trends of modern architecture and interiors.

  Currently, cement slab products that are commercially available are typically made from a kneaded mixture containing cement, quartz sand, large aggregate pieces (or coarse aggregate pieces), a water reducing agent and water. Large aggregate pieces are included to make up the mass, and their sizes can vary from about 3 mm to 10 mm or larger. Stone chips are often used as large aggregate pieces. The water reducing agent can be a fluidizing agent based on a polycarboxylic acid ether polymer.

  The strength of the materials used to make tiles has improved relatively recently, making it possible to make tiles from a single large thin slab, similar to a marble or granite slab. It can be cut to produce square or rectangular tiles of the desired size.

  Large slabs are formed in individual molds and then subjected to a vibration process. As a result, the finest particles move to the mold bottom. The slab becomes the shape or shape of the surface of the formwork. This is known as a “off-form” material.

  Such a manufacturing method has made it possible to give a wide flexibility to variations in the size and thickness of square and / or rectangular tiles. Cutting tiles from a single slab allows the creation of square and / or rectangular tiles of different sizes, which were previously made in small individual molds. The flexibility in fabrication allows the tiles to be sized as desired by the client, without extensive rework or holding a large number of different sized forms in stock. In addition, it is possible to finish tiles more accurately and better by elaborate machining.

  In addition to the above advantages, cutting large slabs into smaller tiles has the advantage of maintaining the natural aesthetic quality inherent in large types of slabs. When separated, the smaller tiles have a unique appearance that improves the visual impression when large surfaces such as walls and floors are covered with smaller tiles.

  After kneading the material, this material is driven into a large mold and the kneaded product is vibrated on the spot. In the kneading in which the fluid is added to activate the bonding step, the kneaded product is placed on the mold and cured to a sufficient extent that the slab can be removed from the mold.

  The formwork is typically stored in a location where the material can solidify and cure prior to cutting. The storage period of the wet-kneaded slab is about 1 to 4 weeks until the slab is fully cured and the material is cut.

  In the case of a large slab that has been naturally cured, when it is sufficiently cured, it is demolded, laminated and cured. Curing can take up to 4 weeks depending on the method and effectiveness of the curing process.

  Of course, in order to allow the slab material to be cured for a sufficient time before the cutting process, it is necessary to move the slab placed from the placement line to the storage area. Generally, the slab remains in the frame after removal from the formwork and is packaged for curing. This involves interrupting the manufacturing process and providing sufficient storage space to store the slab for curing, as well as removing the slab from the formwork and installing it in the storage location for curing. Requires manual intensive process.

  The slab is cut into tiles after calibrating the thickness. After cutting, the tile is “tuned” to create more accurate sides, and the edges of the tile are chamfered or ground to eliminate chipping damage that normally occurs during the cutting process. Thereafter, the individual tiles are subjected to processes such as washing, drying and packing before being shipped for sale.

  The cutting process and subsequent operations are generally performed on a continuous automatic production line.

  As a result, cement or concrete tiles can be juxtaposed and placed in the same way as marble, granite and / or porcelain tiles. Furthermore, the tiles processed in this way generally have a higher quality of installation.

  However, current methods for producing tiles have many significant challenges.

  For example, slab processing (cutting, calibration, grinding and / or adjustment) is generally performed using a diamond cutting tool such as a cutting blade, a calibration tool, or the like.

  When cutting a slab, which is a very hard material, the edges of the cut are subjected to various degrees of chipping and become rough edges. Furthermore, slabs and / or tiles are prone to cracking and breaking during the cutting and proofing process. Stress can cause chipping and breakage, especially at the weakest corners of cement slabs or tiles. Chipping, cracking and / or breakage can result in loss or the need to repair damaged material. This can be costly and time consuming.

  Another disadvantage is that processing is difficult and requires care by a skilled operator to improve losses due to chipping, cracking and / or breakage. Such skilled operators are costly and tile production from slabs is time consuming and interrupts the production process.

  After the calibration and cutting steps, the slab product is generally stored again for complete curing, which requires an additional 3 to 4 in a controlled environment before shipping the product to the installation destination. Weekly storage is required. Further storage of slab products for final curing requires additional handling and storage costs.

  Other drawbacks in current fabrication techniques are the need for expensive equipment for cutting (such as diamond tools and large capital equipment), high energy costs (eg electricity), and the process of processing slabs into products There is a lot of water. It is not uncommon for a calibration device to cost over $ 400,000, and including a cutting line is expected to cost about $ 700,000 to $ 1 million.

  The cutting and calibrating processes also result in a large amount of waste that can be generated as material is removed during the cutting and calibrating processes. Therefore, the waste must be separated from the water used for processing before the water is reused. The separated waste must be collected, processed and disposed of, which can be laborious and / or costly. In this regard, the cost of the water filtration system is expected to be approximately $ 100,000 to $ 200,000. Furthermore, since most facilities require a multipurpose power source, the operating cost for the electrical energy consumption of the entire facility is generally enormous.

  When cutting small tiles or mosaic pieces, the cutting process can be particularly lossy because the diamond cutting blade removes about 3 to 5 mm of material each time it is cut. When producing many tiles from a slab, the total amount of material removed during the cutting process is enormous.

  Typically, the preparation of a slab and tile production plant is a costly business and planning, preparation, construction and installation takes a lot of time. Factory floors must be specially adapted to accommodate heavy equipment built for specific purposes, and drainage systems for collecting, separating and treating waste from water for each plant And a wastewater tank is needed. In addition to all the above drawbacks, the construction of a factory with a special purpose drainage system itself is very costly and therefore hinders the establishment of a manufacturing facility.

  A product that replaces slabs and tiles produced in this way is natural stone. However, natural stone has many elements that can change, and it is difficult to control this. Stone can be inconvenient for certain purposes because it is too soft, too hard, too porous, or too grainy. Furthermore, such materials may not be attractive to customers in terms of aesthetics or may not be suitable for a particular application.

  Another problem with current fabrication methods is that the tile (or slab) is subjected to white flower. White flower is a constant problem in cement products. White flower produces soluble salts and other water-dispersible materials on the surface, but these are not usually bound as part of the cement stone. White flower is generally white and is seen as a deposit of salt formed on the surface, the components appear in solution from the inside of either concrete or masonry, such as carbonation or evaporation It was continuously deposited by this reaction. White flower does not detract from the quality of concrete, but the impact on the aesthetic quality of the product is a costly issue for the industry.

  There are two main types of white flower, primary white flower and secondary white flower. Primary white flowers and secondary white flowers are distinguished mainly by the time of occurrence. Primary white flower is caused by excess water in the concrete production process and is typically expressed during the first 48-72 hours.

  Secondary white flowers occur when moisture penetrates the surface and dissolves soluble calcium salts. The main chemical reaction is the same as primary white flower, which is the conversion of calcium hydroxide to calcite. Secondary white flowers are due to reactions in solution, usually due to rain or condensation, and are therefore less uniform by nature, whereas primary white flowers remain behind deposited salt. Caused by evaporation.

There are three conditions for white flower to occur:
(1) There is a soluble salt;
(2) water can transport salt in solution; and (3) there is a path for the solution to move to the surface (and water evaporation).

The most common white flower salts include calcium carbonate, sodium sulfate, and potassium sulfate, the most harmful being calcium carbonate. In the cement hydration process, calcium hydroxide, Ca (OH) ₂ , slightly soluble in water is formed. Ca (OH) ₂ dissolves and is transported to the concrete surface where it reacts with carbon dioxide, CO ₂ to form calcium carbonate, CaCO ₃ and further water in the air:
Ca (OH) ₂ (dissolved) + CO (dissolved) → CaCO ₃ (solid) + H ₂ O (liquid)

The water evaporates, leaving insoluble CaCO ₃ on the surface. In most cases, the residue is not simply washed away with normal water, but needs to be weakly acidic and / or abrasive to remove. White flowers that arise from sodium or potassium salts are more easily removed because they are water soluble.

  Salts that may form white or “fluffy” deposits or discoloration can be washed away and removed using a suitable agent such as phosphoric acid. The acid can be neutralized with a lightly diluted neutral detergent and then rinsed well with water. Thus, the cleaning process may require considerable effort depending on the degree of white flower. Furthermore, if the water permeation source is not specified, there is a risk that white flower will appear again. In general, if a tile received from the manufacturer shows any signs of whiteness, the handler tends to discard the tile as a precaution against discoloration that cannot be removed or will reoccur at a later date.

  The main factors affecting white flower generation include cement content, kneaded water, water / cement ratio, admixture, curing conditions, and water permeability. When the cement content increases, the possibility of white flower generation tends to increase.

  The kneaded water may contain various amounts of calcium, magnesium, potassium, or sodium that contribute to the possibility of white flower generation. In particular, the white flower is caused by water softened by ion exchange, and in the process of this ion exchange, calcium ions and magnesium ions are respectively substituted into two (more water-soluble) sodium ions. Become.

  The water / cement ratio is another important factor. This is because as the water / cement ratio increases, the concrete substrate becomes more porous, thereby adding surplus water and easily forming a pathway, thereby increasing the likelihood of white bloom.

  Admixtures that enhance flowability have been proposed to help optimize the cement content and water / cement ratio in manufactured concrete products.

  Permeability is also closely related to white flower. The lower the water permeability of the concrete base material, the lower the possibility of white flower generation. By impregnating the material with a hydrophobic sealer and treating it, the cement product can be protected from white flower. Sealers are generally water repellent and penetrate deep into the material, keeping water and dissolved salts well away from the surface. Admixtures that repel water (block pores) have been proposed to reduce water permeability by reducing the water transport (absorption) of concrete parts by water repellency. Permeating the sealer not only “shales” water vapor but also stops salt molecules from moving out. However, in climates where freezing is a concern, such sealers can be damaged from repeated freeze / thaw cycles.

  Proper curing of concrete products is essential to improve cement hydration and strength. Typically, steam is used to provide high humidity and high temperature conditions to accelerate the curing cycle. In some cases, carbon dioxide is injected into the concrete substrate. Theoretically, this creates white flower below the surface and blocks the path for further white flower on the outermost layer. However, this process can be difficult to control due to various different factors such as product density, absorption rate, moisture content, air circulation, and humidity level.

  Careful curing at the factory can help minimize white flower. However, in the process of processing a slab, a large amount of water is used, and this water brings calcium hydroxide to the surface, and calcium hydroxide may react with carbon dioxide in the atmosphere on this surface to produce white flower. In this case, it is necessary to remove white flowers. In addition, various levels of white-stain stains often occur during transportation. This is the case when container-type transport is used in the transport process and the material is subjected to extreme temperatures and temperature changes. Further, when container-type transportation is used, condensation may occur or moisture may be drawn from the material or the surroundings by heat to create an environment that promotes white-fouling.

  Occasionally, white-stained stains may be reduced. However, even a small amount of white stain can be sufficient to change against the original color of the material and / or the intended finish. Currently, in order to minimize this problem, it is common to store the product in the factory to a practical extent before shipping the product. It is also a common requirement to instruct customers how to store materials in a satisfactory manner in order to minimize the conditions under which white flower occurs.

  Most concrete pavement manufacturers have attempted to control the white flower problem by using admixtures in their products. However, no manufacturer has completely solved this problem. As a result, most contractors rely on the use of commercial white flower cleaners. Most cleaning agents effectively reduce the whitish turbidity caused by white flower on the pavement, but only when used properly. Many of these products are based on mixtures of neutral detergents and acids that “eat” or “dissolve” the insoluble carbonate and wash it away. However, some acids can react oppositely to the pigments used to color concrete and signal discoloration. In addition, such acids can actually exacerbate the problem by removing the blocked capillaries and micropores, so that in this case calcium hydroxide can find a way back to the surface. Become. Furthermore, the use of such cleaning agents can be very labor intensive and time consuming.

  Current packaging techniques include coating the entire plate of the tile or slab with a polystyrene sheet to prevent the tile or slab from reacting with atmospheric components.

  White flower is highly undesirable because ugly stains are a concern for customers. The customer may consider white flower as a defect in the product and may require detailed instructions for cleaning white flower stains from the product.

  It is an object of the present invention to at least ameliorate one or more of the above-mentioned drawbacks associated with making cement slabs and tiles.

  References to any prior art (prior art or prior art techniques) cited herein are part of the general knowledge of one of ordinary skill in the relevant arts of the present invention claimed herein. It is not something that recognizes or presents, and should not be considered as such.

  In one aspect, the present invention includes applying a protective layer to at least one surface of the slab product and allowing the protective layer to be held in place when the cement kneaded product is cast into a mold. Provide a method for processing cement products.

  In one embodiment, the protective layer is a mold liner. The protective layer is applied to the surface of the mold before placing the material for the slab product. The protective layer is a relatively thin sheet made of a plastic material.

  In one embodiment, the protective layer is applied to the surface of the mold before casting the mixture into the mold, and the device for reducing the possibility of air entering between the mold surface and the protective layer Can be securely attached to the surface of the formwork.

  In one embodiment, the protective layer is cut when the slab product is cut, so that the protective layer remains attached to the slab product after demolding.

  In another embodiment, when the slab product is demolded, the slab product with the protective layer may be evacuated or replaced with another fluid before sealing the container. Inserted into any of the sealed containers.

  In another embodiment, since the slab product is not removed from the formwork, the protective layer remains attached to the slab product. The overhanging edge of the protective layer is wrapped around one or more side edges of the slab product. The overhanging liner edges are sealed together using a heat sealer or shrink wrap sealer or the like to prevent air from passing to / from the slab through the sealed protective layer. .

  In another aspect, the invention includes inserting the slab product into a sealed container, evacuating substantially all of the air, and sealing the container before the slab product is fully cured. Provide a method for processing slab products.

  In one embodiment, the slab product is vacuum packed in a plastic bag.

  In one embodiment, the slab product is vacuum packed using a vacuum sealer to remove air from inside the plastic bag.

  In yet another embodiment, the slab product is vacuum packed using a chamber vacuum sealer to replace the air inside the plastic bag with a suitable gas to prevent whiteness. The gas can be a heavy gas such as carbon dioxide.

  In yet another embodiment using a mold liner, the slab product is demolded and the mold liner is held intact in the mold. The slab product is then inserted into a package that is then sealed to prevent or substantially reduce air and / or moisture from passing through the seal.

  In yet another aspect, the present invention includes a slab comprising inserting a slab product into a sealed container and replacing substantially all of the air with another fluid or substance prior to sealing the container. Provide product processing methods.

  It will be appreciated that the term “cure” can be substituted for the term “set”. It will also be appreciated that the term “semi-set” has virtually the same meaning as “semi-plastic” or “semi-hardened”.

It is a figure which shows the kneading tank which put the structural member of the mixture before the kneading | mixing process. It is a figure which shows the foundation | substrate and mold liner of a mold before attachment. It is a figure which shows the foundation | substrate and mold liner of the formwork of the same attachment process. It is a figure which shows a mode that a formwork holding wall is given to the foundation | substrate which attaches a mold liner. It is a figure which shows a mode that a mixture is cast in a formwork. It is a figure which shows the material slab in the mold form in the process of a cutting process in a semi-solidified state. It is a slab product which arises from the cutting process shown in FIG. 6, and is a figure which shows the slab product which removed and removed the formwork holding wall. It is a figure which shows the external appearance of the cut end of a prior art material slab. It is a figure which shows the external appearance of the cut end of material slab by one Embodiment of this invention. It is a figure which shows a mode that it was a demolded slab product and removed the lining of the formwork. It is a slab product that has been removed from the mold, and shows a state in which the lining of the formwork is left attached to the slab product. It is a figure which shows the protective layer given to the at least 1 surface of a slab product. It is a figure which shows the protective layer given to the at least 1 surface of a slab product. It is a figure which shows the slab product vacuum-packaged in the plastic bag.

  It should be noted that all of the following considerations describe specific embodiments, but are exemplary in nature and not limiting.

  The present invention relates to tiles (interior, exterior, floor and wall; conventional and alternative types of tiles); paving coverings for walls (both interior and exterior) mosaics (such as floor mosaics); kitchen bench tops Kitchen counters, kitchen benches, kitchen islands; table tops; integral cast products for tilt-up panels such as scott systems; curtain walls and exterior coverings optionally with accessories such as products containing fibers; Materials; Insulating tiles; Other slab products for the slab market; Furniture; Cement slabs and / or tiles made from them that can be used for roof tiles or slabs and / or tiles for other suitable applications About

  An example of a method for producing a cement slab according to the present invention includes a step of kneading cement, a fine bone material, a fine bone material, and water.

  FIG. 1 shows a kneading tank (10) containing materials such as cement (12), fine aggregate (14) fine aggregate (16) and crushed or crushed material (powder) (17). In the exemplary embodiment of FIG. 1, the kneading vessel (10) is also shown having three piles of pigment (18) contained in the kneaded product to achieve the desired color of the finished material slab.

  The fine bone material (14) and / or the fine bone material (16) may be a siliceous material comprising sand. Further, the cement kneaded material may include a crushed bone material or a crushed bone material (powder) (17), and the crushed material in this case may be sand.

  In order to reduce the water content of the cement kneaded product, a fluidizing agent having a water reducing action can be added, and the fluidizing agent can be a polycarboxylic acid ether polymer. The amount of fluidizing agent having a water reducing action can be between about 1 and 5% based on the weight of the cement kneaded material. For example, if the cement content of the cement kneaded product is 100 kilograms, the amount of water-reducing fluidizing agent can be between about 1 kilogram and 5 kilograms. The water-cement ratio when using a fluidizing agent having a water reducing action can be about 0.24 to 0.26.

  The ratio of cement (12), fine bone material (14) and fine bone material (16) can be 2: 2: 1. For example, a cement mix can include 100 kilograms of cement, 100 kilograms of fine bone material, and 50 kilograms of fine bone material. Furthermore, in embodiments where the cement kneaded material includes either ground bone material or powder, the ratio of cement, fine bone material, fine bone material and ground sand / or powder is 10: 10: 5: 2. be able to. For example, a cement mix can include 100 kilograms of cement, 100 kilograms of fine bone material, 50 kilograms of fine bone material and 20 kilograms of osteoclast material or powder.

  Of course, the exact material ratio of any kneaded product that yields optimal results will depend on the quality and suitability of the material, the quality of any polycarboxylic acid admixture and the efficiency of the kneading equipment.

  In yet another embodiment, a buffer such as vinegar and / or ethanol is added to the cement knead to reduce surface tension. This buffer is included to reduce the air content of the cement kneaded product. The air contained in the cement kneaded material is generally in the form of bubbles, and the vinegar and / or ethanol reduces the bubble content of the cement kneaded material. The ratio of vinegar and / or alcohol to cement can be about 0.075.

  The cement kneaded product can be kneaded in a standard commercial dough mixer equipped with a kneading tank (10) and a mixing head (20) until it is completely wetted. The kneading time can be about 3 to 5 minutes.

  FIG. 2 shows a base (24) of a glass sheet formwork. A sheet of appropriately sized mold liner (26) is cut from the roll of liner material (28) and placed on the mold substrate (24). Next, as shown in FIG. 3, a liner (26) is applied to the upper surface of the base (24) of the mold. The liner (26) is securely applied to the substrate (24) to prevent or at least minimize the possibility of air entering between the liner (26) and the formwork substrate (24).

  When the mold liner (26) is applied to the base (24) of the mold, the acrylic material is taken out from the tube container (28) to form the mold holding wall (30) (see FIG. 4). The height of the formwork holding wall (30) varies depending on the required slab depth. In FIG. 5, the slab material (32) is driven from the kneading tank (34) into the mold.

  The shape and size of the formwork may vary and may be made from a variety of materials such as aluminum, steel, timber, plastic, glass and / or acrylic.

  The mold lining helps to prevent damage to the mold by the cutting tool and can be discarded or replaced after the demolding process. The mold liner can be formed of plastic, wax paper or any material suitable for this process.

  The cement mix can be substantially self-leveling when in the mold. The self-leveling process may take about 2 to 6 minutes continuously. Furthermore, air and air bubbles escape from the cement kneaded product in the process of self-leveling. About 80% to 95% or more of air and bubbles are expected to escape from the kneaded product during the untouched self-leveling process.

  Further reduction of air and bubbles can be achieved by lightly vibrating the formwork containing the cement mix. The cement kneaded product can be vibrated until air and air bubbles do not substantially escape to the surface of the cement kneaded product. In this regard, the light vibration can be about 3 to 10 seconds.

  Following leveling and vibration of the cement kneaded product, the cement kneaded product is solidified until it is substantially semi-solidified (or substantially semi-cured). When semi-solidified, the cement material or cement slab is cut into tiles or other desired products. Because of the semi-solid state, the cement material can be cut using a knife or other sharp cutting tool that vibrates at a predetermined frequency.

  The predetermined frequency can be an ultrasonic frequency, which can be in the range of 20 kHz to 40 kHz. The ultrasonic cutting tool may be handheld or incorporated into an automated machine, such as a computer controlled automatic cutting machine.

  It will be appreciated that using a blade vibrating at an ultrasonic frequency should result in very little or substantially no cement material adhering to the blade when cutting. This eliminates the need to clean the blade and should eliminate or substantially eliminate the cement material that is removed from the slab during the cutting process.

  FIG. 6 shows a diagram of the cutting process, in which the slab material (32) is cured until it is in a semi-solid state, and the cutting device (36) controlled by the robot arm is oscillated. The cutting tool (38) is passed through the slab material (32). The path 40 is cut through the slab material (32).

  FIG. 7 shows a view of the slab product (42, 44) produced by the cut 40 through the material slab. Furthermore, in FIG. 7, the formwork holding wall (30) is removed, which is done by removing the formwork holding wall (30) from the slab. In this regard, by selecting a sufficiently malleable material for the formwork retaining wall (30), it can be cut in the same way using the vibration cutting tool (38).

  The ultrasonic cutting tool (38) can be a thin blade that can cut the cement material but does not substantially remove the cement material from the slab. Furthermore, the material can be cut at a rate of about 300 to 800 mm per second.

  It should be understood that other cutting techniques may be used as an alternative to ultrasonic cutting when the cement slab is in a semi-solid state.

  The cement material can be cured until it is substantially semi-solidified, followed by self-leveling and / or vibration. This curing process portion can be about 30 minutes to 1 hour at an ambient temperature of about 21 degrees Celsius. Higher ambient temperatures may accelerate the curing time. The cement slab may be cut at any time after the cement material is driven into the mold, but the cement material must be flattened and cured sufficiently to make the cement material semi-solidified. It is important to understand that more time must be taken to allow air to escape and / or be removed.

  For cement materials, make sure that the material does not move substantially and / or does not fuse together around the cut when the material is cut by applying a cutting machine to the cement material Thus, the suitability for cutting can be evaluated.

  Since the cement slab is cut when it is substantially semi-solidified, the stress on the cement material is substantially reduced compared to previous cutting methods when the cement slab is substantially hardened. You will understand. Thus, chipping and breakage of the cement slab should be substantially reduced or eliminated because the stress on the cement material is reduced. Furthermore, little or substantially no cement material is removed from the cement slab during the cutting process of the present invention.

  The cement slab may be cut into tiles that vary in size and shape. The shape may include a curved shape and a circular shape, and the tile may be made to have a sharp corner. Furthermore, cutting the cement slab while in a semi-solid state does not require the use of expensive cutting equipment such as a diamond tool, thereby reducing the cutting time. Also, the amount of water required for cutting can be substantially reduced or eliminated entirely. This has the new advantage that little or no wastewater has been produced that previously required costly treatment and / or disposal.

  The method of the present invention can be used to prepare a slab material from which it is possible to cut shapes, angles and sizes that were previously considered impossible or too problematic. .

  Since this process does not require high pressure water during the cutting and calibration process, the stress on the slab is substantially reduced, thereby reducing damage. Thus, the slab can be cut into thin pieces.

  Cement slabs may be cut to a thickness of about 3 mm to 5 mm, which can create new and innovative products.

  Further, the material can be substantially strengthened as a result of less stress on the product during the processing. Similarly, this can reduce problems such as breakage of corners during product installation.

  In addition, since a large aggregate piece is not used for producing a cement material, there is a possibility that problems after installation related to slow progress of cracks (hairline crack, etc.) may be reduced. In the case of the slab product produced according to the present invention, it is expected that the cut end will have a more pleasant and beautiful appearance as compared to the previous product in which the kneaded material contained large aggregate. FIG. 8A shows an example of a cross-section of a slab product cut according to the current manufacturing method. In this figure, the size and shape of the large aggregate occupy most of the appearance. In contrast, FIG. 8B shows an example of a cross section of a slab product cut according to the present invention, which is expected to be more widely accepted for use when the cut is visible.

  For cement slabs, thickness consistency can also be evaluated and / or calibrated while in a semi-solid state. Any area of the cement slab that is thicker (higher) than desired can be removed. The removal can be performed with a cheese grated type device. However, any requirement to evaluate and / or calibrate the thickness of the cement slab and / or remove material from the thicker area of the slab is substantially reduced by the method of making a slab according to the present invention, Or you will see that it should be gone.

  To flatten the thickness, evaluating and / or calibrating the thickness and / or removing the cement material can be done before cutting the slab or after cutting the slab into tiles. However, calibration and / or evaluation and / or removal of the cement material must be performed while the cement slab is in a semi-cured (semi-solidified) state.

  After cutting the cement slab, the tile is stored for about 20 to 24 hours, thereby further curing the tile. The tile is cured and can be removed from the formwork.

  The demolded tile is then packaged and fully cured.

  9A and 9B show the demolded slab product. In the case of FIG. 9A, the mold liner has been removed from the slab product (46). This can be done during demolding when the slab product (46) is removed but the liner is held in place. Instead of doing this, as shown in FIG. 9B, when the mold liner is cut when cutting the slab product, the liner (50) remains adhered to the slab product (48) after demolding. Thereafter, the liner (50) may be removed from the slab product (48) or may be held in place to protect the slab product (48) during subsequent handling and shipping.

  The demolded slab product is then packaged and fully cured. Full curing allows the tile cement material to have maximum strength during packaging. The packaged product can then be transported and / or shipped while being cured. This reduces or eliminates the need for product curing at the factory. In addition, white stain can be substantially reduced or eliminated.

  When the liner (50) is held on the slab product (48), the liner acts as a protective layer against the top surface of the slab product (48) until the product is fully cured. In the course of the cement hydration process, which is performed until the slab product (48) is completely cured, calcium hydroxide is in a liquid state. The liner (50) builds a barrier on the top surface of the slab product (48) to prevent the calcium hydroxide from being exposed to carbon dioxide in the air and to react with the carbon dioxide to form calcium carbonate. . In this way, primary white flower is prevented from being generated on the surface provided with the liner.

  The upper surface means a surface that is visible when the slab product (48) is laid down. White base may still appear on the unprotected bottom and / or side edges, but this will not be visible when the product is laid down, which will affect the aesthetic appeal of the product during installation. There is no effect. If the liner (50) is removed and the slab product (48) is installed, it is considered that an appropriate sealer can be applied to the upper surface of the slab product (48) to prevent secondary whiteness if necessary. .

  FIG. 10A shows an example of packaging a product for transport and / or storage using a liner (50) that remains attached to an uncut slab product (48). A liner (50) that is larger than the size of the uncut slab product (48) is placed on the bottom of the slab. Next, the overhanging edge (51) of the liner (50) is wrapped around the edge of the slab product (48) so that the overhanging edge (51) wraps around the side edges and is on the top surface of the slab. The overhanging edge (51) can be secured in place via heat shrink wrapping, heat sealing or any other suitable means.

  An alternative application of liner (50) for packaging slab product (48) is shown in FIG. 10B. In the case of FIG. 10B, the mold liner has been removed from the slab product (46) upon demolding, in which case the slab product (46) is removed but the liner is held in place. The liner (50) can be applied to both the top and bottom surfaces of the slab product (46). A sheet of appropriately sized liner (50) is cut from the roll of liner material (55) and placed over the top and bottom surfaces of the slab product (46). The liner (50) is then heat sealed along the open side edges to package the slab product (46) into the liner material (50). By applying the liner (50) in this way, all surfaces of the slab product (46) are protected from primary whiteness. Next, once the product is installed, a suitable sealer can be applied to the top surface of the slab product (46) to prevent or at least substantially reduce secondary whiteness.

  In yet another embodiment, the uncut slab product and the cut slab product, from which the liner (50) has been removed during the demolding process, are vacuum packed into a sealed container. According to some embodiments, as shown in FIG. 11, a plastic bag is used to vacuum pack the slab product. The plastic bag (60) is of a size suitable for packaging one or more slab products (46) therein. The slab product (46) is preferably packaged separately to prevent two or more slab products (46) from rubbing against each other and leaving scars on the slab product (46).

  The slab product (46) is placed in a plastic bag (60) and then the plastic bag (60) is vacuum sealed to remove substantially all of the air from within the bag. Immediate removal of air and moisture around the face of the cement slab product (46) minimizes the potential for substantial whiteness.

  The present invention provides a controlled environment for storage prior to delivery in order to ensure optimal conditions that reduce the formation of excessive condensation that returns water to the slab product (46) and promotes water movement. This is primarily achieved by keeping the freshly manufactured slab product in an environment that prevents or at least substantially minimizes any condensation. Since the moisture in the slab material cannot escape, the present invention provides an environment that reduces white flower and maximizes effective curing.

  In another embodiment, the plastic bag (60) is sealed using a chamber vacuum sealer. In this embodiment, consider a slab product having a liner (50) affixed to one or more sides of the slab product (46). The chamber vacuum sealer removes air from the interior of the plastic bag (60) and replaces the air with another more desirable gas. Packaging can include replacing the air in the packaging with a heavy gas such as, for example, carbon dioxide.

  Carbon dioxide injected in the absence of oxygen under pressure may have the advantage of reacting with liquid calcium hydroxide in the cement material to produce solid calcium carbonate. The addition of carbon dioxide has the effect of reducing white flower through the process of “capillary blockage”, whereby the fine pores and spaces in the concrete substrate that are the way in which soluble calcium hydroxide is transported, Eventually it becomes clogged with deposits of insoluble calcium carbonate. When tiles are packaged in this way, some white flower may form under the tile surface, but in this case, the white flower effectively blocks the calcium hydroxide escape path and causes some further reaction. “Containment”, by making whites appear to occur under the tile surface, disappear. In this way, the problem of white flowers that impair the aesthetics of the surface is reduced or eliminated.

  In yet another embodiment, when packaging tiles, this process may include using a fluid or other suitable substrate. According to some embodiments, before or during packaging, any one of the various methods described herein may be used to add sodium metasilicate or potassium metasilicate. Apply mist as a base to the surface of the product. The addition of sodium silicate / potassium silicate also has the effect of reducing white flower through a “capillary blockage” process by reacting with free calcium hydroxide to form calcium silicate. By “filling” the capillaries and pores, water is prevented from moving to the surface, thereby reducing the occurrence of white flower on the surface. Calcium silicate can be a substance that is harder and less susceptible to chemical reaction than calcium carbonate.

  This reaction can also occur below the surface. The packaging process may include injecting heavy gas and sodium silicate and / or potassium silicate vapors into the vacuum package.

  The present invention embodies various advantages. By minimizing white flower at the production, curing, storage and transport stages, slab products can be delivered to the site with ready installation without the need for cleaning prior to use. Furthermore, the processing of the slab product according to the present invention allows the slab product to continue to be cured in the middle of transportation, eliminating the need to store the product in a controlled environment in an attempt to avoid contamination with white flower or water. Maintaining the slab product in good condition prevents a handler or customer from rejecting the product for appearance reasons, thereby reducing losses and costs caused by wasted product disposal. By eliminating the need to store slab products during curing, costs associated with storage floor space are also reduced.

  Prevention is better than repair, both in terms of cost and in situations where remedial measures are required repeatedly for the appearance of new white flowers. Accumulation of the effects of repeating the latter can cause structural damage over time.

  While several exemplary embodiments have been described, such embodiments are merely illustrative and are not intended to limit the invention, and the invention is not limited to the specific designs and configurations described herein. It should be understood that the invention is not limited to. This is because various other changes, combinations, omissions, corrections and replacements are possible in addition to those described in the above paragraph. Those skilled in the art will recognize that various adaptations and modifications of the above embodiments can be made without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.

Claims (18)

  A method for processing a cement product, comprising: applying a protective layer to at least one surface of a slab product when the cement kneaded material is placed in a mold, and holding the protective layer in place.   The method of claim 1, wherein the protective layer is a liner.   The method of claim 1, wherein the protective layer is applied to the surface of the formwork prior to placing material for the slab product.   The method according to claim 1, wherein the protective layer is a relatively thin sheet made of a plastic material.   The method of claim 3, wherein the protective layer is applied to the surface of the mold using a device for reducing the likelihood of air entering between the mold surface and the protective layer.   The protective layer is cut when the slab product is cut, whereby the protective layer remains attached to the slab product after demolding. Method.   7. A method according to any one of the preceding claims, wherein the overhanging edge of the protective layer is wound around one or more side edges of the slab product.   The method of claim 7, wherein the overhanging edge of the protective layer is sealed by applying heat.   An appropriately sized sheet of protective layer is cut from a roll of liner material, placed on top and bottom surfaces of the slab product, and heat sealed along open side edges to wrap the slab product. The method according to any one of 1 to 8.   A method for processing a slab product comprising inserting the slab product into a sealed container, exhausting substantially all of the air, and sealing the container before the slab product is fully cured.   The method of claim 10, wherein the slab product is vacuum packed in a plastic bag.   The method of claim 10, wherein the slab product is vacuum packed using a vacuum sealer to remove substantially all air from within the sealed container. The method of claim 10, wherein the slab product is vacuum packed using a chamber vacuum sealer to replace substantially all of the air inside the sealed container with gas.   The method of claim 13, wherein the gas is a heavy gas.   The method according to claim 13 or 14, wherein the gas is carbon dioxide.   The slab product is vacuum packed using a chamber vacuum sealer to replace substantially all of the air inside the sealed container with another fluid or substance prior to sealing the container. 10. The method according to 10.   17. The method of claim 16, wherein a sodium metasilicate or potassium metasilicate substrate is applied to the surface of the product prior to packaging or during vacuum packaging.   The slab product processed by the method as described in any one of Claims 1-17.

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